Module Backbone System

ABSTRACT

An apparatus and battery system are disclosed. The apparatus includes a first panel, a first bus bar, and a second panel. The first panel includes a first upper surface and a first lower surface. The first upper surface includes a first cavity extending into the first upper surface towards the first lower surface. The first bus bar is within the first cavity. The second panel has a second lower surface in direct contact with the first upper surface. The second lower surface extends over a substantial portion of the first cavity.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of Huff et al., U.S. Pat. No.9,960,396, issued May 1, 2018, the entirety of which is incorporatedherein by reference, and which claims the benefit under 35 U.S.C. 119(e)to application Ser. No. 61/960,715 titled “Module Backbone System” andfiled on Sep. 24, 2013, the entirety of which is incorporated herein byreference. Moreover, this application is related to application Ser. No.61/962,329 titled “Charger to Vehicle Remote Access System” and filed onNov. 4, 2013, the entirety of which is incorporated herein by reference.Further, this application is related to application Ser. No. 61/965,606titled “Separate Traction/Hydraulic Drive Systems” and filed on Feb. 3,2014, the entirety of which is incorporated herein by reference.Additionally, this application is related to application Ser. No.61/997,186 titled “Module Maintenance System” and filed on May 23, 2014,the entirety of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to a battery system (e.g., battery pack),particularly a battery system for high voltage applications.

2. Description of Related Art

Some battery systems utilize an exposed bus bar. In such systems, asingle cell of a pack of cells may be replaced by accessing the exposedbus bar. However, maintenance of such systems may be expensive and timeconsuming. For example, such systems may require a trained technicianand specialized equipment due to a risk of accidental contact with theexposed bus bar. Moreover, such systems may require access to tools andequipment found in a laboratory remote from the battery system.Furthermore, such systems may require the entire pack to be offlineduring repairs.

Therefore, there is a need in the art for a battery system that iseasier to repair, requires less sophisticated equipment, and has areduced offline time for repairs.

SUMMARY OF THE INVENTION

The proposed invention is directed to a battery system. In one exemplaryembodiment, a battery system is formed of 144 cells, but this technologycan use a pack having any number of cells. Moreover, in the exemplaryembodiment, the battery system uses a pack formed of 12 modules, butthis technology can use a pack having any number of modules (e.g.,2-16). In one example, a battery module has a nominal voltage of 40volts (V), 260 ampere-hour (Ah), and 10 kilowatt hour (kWh). Further,this system may use various battery cell types, manufacturers,technologies, etc.

Embodiments include a bus bar system flexibly connected to a panel. Inone embodiment, a first panel and a second panel may prevent contactwith a bus bar system to simplify repair. Moreover, in some embodiments,coupling elements used to connect a battery system to the bus bar systemare configured to prevent accidental contact. Accordingly, in someinstances, replacement of one or more batteries of a battery system maybe quickly and easily replaced without sophisticated equipment ortechnical expertise.

In one aspect, an apparatus includes a first panel, a first bus bar, anda second panel. The first panel includes a first upper surface and afirst lower surface. The first upper surface includes a first cavityextending into the first upper surface towards the first lower surface.The first bus bar is within the first cavity. The second panel has asecond lower surface in direct contact with the first upper surface. Thesecond lower surface extends over a substantial portion of the firstcavity.

In another aspect, an apparatus includes a first panel, a first bus bar,a second panel, and a second bus bar. The first panel includes a firstupper surface and a first lower surface. The first upper surfaceincludes a first cavity extending into the first upper surface towardsthe first lower surface. The first upper surface includes a secondcavity extending into the first upper surface towards the first lowersurface. The first cavity is spaced from the second cavity. The firstbus bar is within the first cavity. The second bus bar is within thesecond cavity. The second bus bar is configured to move within thesecond cavity. The second panel has a second lower surface into directcontact with the first upper surface. The second lower surface extendsover a substantial portion of the first cavity. The second lower surfaceextends over a substantial portion of the second cavity.

In yet another aspect, a battery system includes a backbone, a firstbay, and a second bay. The backbone includes a first panel, a first busbar, and a second panel. The first panel includes a first upper surfaceand a first lower surface. The first upper surface includes a firstcavity extending into the first upper surface towards the first lowersurface. The first bus bar is within the first cavity. The first bus barincludes a first coupling element and a second coupling element. Thesecond panel has a second lower surface in direct contact with the firstupper surface. The second lower surface extends over a substantialportion of the first cavity. The first bay is for a first battery moduleand includes a first guide pin. The first coupling element extends intothe first bay. The second bay is for a second battery module andincludes a second guide pin. The second coupling element extends intothe second bay.

Other systems, methods, features and advantages of the invention willbe, or will become, apparent to one of ordinary skill in the art uponexamination of the following figures and detailed description. It isintended that all such additional systems, methods, features andadvantages be included within this description and this summary, bewithin the scope of the invention, and be protected by the followingclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention can be better understood with reference to the followingdrawings and description. The components in the figures are notnecessarily to scale, emphasis instead being placed upon illustratingthe principles of the invention. Moreover, in the figures, likereference numerals designate corresponding parts throughout thedifferent views.

FIG. 1 is a schematic view of a backbone, in accordance with anexemplary embodiment;

FIG. 2 is a schematic view of the backbone of FIG. 1 with a bus bar in afirst cavity, in accordance with an exemplary embodiment;

FIG. 3 is a schematic view of the backbone of FIG. 1 with a secondpanel, in accordance with an exemplary embodiment;

FIG. 4 is a schematic view of the backbone of FIG. 1 with a second panelin contact with a first panel, in accordance with an exemplaryembodiment;

FIG. 5 is a cross-sectional view of the backbone of FIG. 4, inaccordance with an exemplary embodiment;

FIG. 6 is a schematic view of a backbone having coupling elementsextending through a first panel, in accordance with an exemplaryembodiment;

FIG. 7 is a schematic view of the backbone of FIG. 6 with a second panelin contact with a first panel, in accordance with an exemplaryembodiment;

FIG. 8 is an isometric view of a battery system, in accordance with anexemplary embodiment;

FIG. 9 is a schematic view of the battery system of FIG. 8, inaccordance with an exemplary embodiment;

FIG. 10 is a first exploded view of a backbone, in accordance with anexemplary embodiment;

FIG. 11 is a second exploded view of the backbone of FIG. 10, inaccordance with an exemplary embodiment;

FIG. 12 is an isometric view of a first side of a backbone, inaccordance with an exemplary embodiment;

FIG. 13 is an isometric view of a second side of the backbone of FIG. 7,in accordance with an exemplary embodiment;

FIG. 14 is a schematic view of a side of a backbone, in accordance withan exemplary embodiment;

FIG. 15 is a schematic view of a top of the backbone of FIG. 14, inaccordance with an exemplary embodiment;

FIG. 16 is a schematic view of a bottom of the backbone of FIG. 14, inaccordance with an exemplary embodiment;

FIG. 17 is a schematic view of a left edge of the backbone of FIG. 14,in accordance with an exemplary embodiment;

FIG. 18 is a schematic view of a right edge of the backbone of FIG. 14,in accordance with an exemplary embodiment;

FIG. 19 is an isometric view of a first side of a battery module, inaccordance with an exemplary embodiment;

FIG. 20 is an isometric view of a second side of the battery module ofFIG. 19, in accordance with an exemplary embodiment;

FIG. 21 is a schematic view the battery module of FIG. 19, in accordancewith an exemplary embodiment;

FIG. 22 is an schematic view of a first side of a battery system, inaccordance with an exemplary embodiment;

FIG. 23 is a schematic view of a second side of the battery system ofFIG. 14, in accordance with an exemplary embodiment;

FIG. 24 is a schematic view of a battery system, in accordance with anexemplary embodiment;

FIG. 25 is an isometric view of a first side of a backbone, inaccordance with an exemplary embodiment;

FIG. 26 is an isometric view of a second side of the backbone of FIG. 3,in accordance with an exemplary embodiment;

FIG. 27 is a schematic view of a method of removing a battery modulefrom a battery system, in accordance with an exemplary embodiment;

FIG. 28 is a schematic view of a method of installing a battery moduleinto a battery system, in accordance with an exemplary embodiment;

FIG. 29 is a schematic view of a method of removing a battery cell of abattery module, in accordance with an exemplary embodiment;

FIG. 30 is a schematic view of a method of installing a battery cell ofa battery module, in accordance with an exemplary embodiment;

FIG. 31 is a schematic view of a battery system having twelve modules,in accordance with an exemplary embodiment;

FIG. 32 is a schematic view of a first battery system having sixteenmodules, in accordance with an exemplary embodiment;

FIG. 33 is a schematic view of a second battery system having sixteenmodules, in accordance with an exemplary embodiment; and

FIG. 34 is a schematic view of a battery system having eight modules, inaccordance with an exemplary embodiment.

DETAILED DESCRIPTION

FIG. 1 illustrates components for a backbone system 100 including afirst panel 102, a first bus bar 104, a second bus bar 106, and a returnbus bar 108. As shown, the first panel 102 includes a first uppersurface 110 and a first lower surface 112.

As previously noted, in some instances, it is desirable to confine a busbar within a cavity to improve safety and to prevent dust and dirt fromaccumulating onto the bus bar. Accordingly, in some embodiments, thefirst upper surface 110 includes a first cavity 114. The first cavity114, as shown, may extend into the first upper surface 110 towards thefirst lower surface 112. In some embodiments, the first cavity 114includes an inner surface 116. As such, the first cavity may allowmovement of the first bus bar 104 within the first cavity 114 therebyconfining the first bus bar 104 within the first cavity 114.

Similarly, in some embodiments, the first upper surface includes asecond cavity to confine the second bus bar and/or the first uppersurface includes a return cavity to confine the return bus bar. Forexample, as shown in FIG. 1, the first upper surface 110 includes asecond cavity 118 to confine the second bus bar 106 and/or the firstupper surface includes a return cavity 120 to confine the return bus bar108. In some embodiments, the second cavity and/or the return cavity aresimilar to the first cavity. For example, the second cavity 118 has aninner surface and/or the return cavity 120 has an inner surface. Inother embodiments, the second cavity and the first cavity are differentand/or the return cavity and the first cavity are different. In someembodiments, the various cavities of the first panel are coplanar. Forexample, as shown in FIG. 1, the first cavity 114 is coplanar with thesecond cavity 118.

The various bus bars may be formed of various materials and techniques,and may have various properties. For example, the first bus bar 104 maybe formed of a conductive material such as copper, aluminum, etc.Moreover, the first bus bar 104 may be formed to have any thickness,length, height, weight, etc. Further, the various bus bars may be rigid.As used herein, a rigid bus bar may have a Young's modulus of greaterthan 50 GPa, greater than 69 GPa, greater than 117 GPa, etc.

In some embodiments, the first bus bar is contained within the innersurface. For example, as shown in FIG. 2, the first bus bar 104 iscontained within the inner surface 116. Similarly, in some embodiments,the second bus bar is contained within an inner surface of the secondcavity and/or the return bus bar is contained within an inner surface ofthe return cavity. In some embodiments, the first bus bar is between thefirst upper surface and the first lower surface. For example, as shown,the first bus bar 104 is between the first upper surface 110 and thefirst lower surface 112. Likewise, in some embodiments, the second busbar is between the first upper surface and the first lower surfaceand/or the return bus bar is between the first upper surface and thefirst lower surface.

In one embodiment, a second panel may be provided to extend over thefirst cavity. For example, as shown in FIG. 3, second panel 121 isprovided over the first cavity 114. In some embodiments, the secondpanel extends over a substantial portion of the first cavity. As usedherein, a panel extends over a substantial portion of a cavity when thepanel extends over more than eighty percent of a surface area of thecavity, more than ninety percent of a surface area of the cavity, morethan ninety-five percent of a surface area of the cavity, etc. Forexample, as shown in the example, the second panel 121 extends over morethan eighty percent of a surface area of the first cavity 114.

In some embodiments, the first panel and the second panel have differentwidths. For example, the first panel 102 has a first width 130 differentfrom a second width 132 of the second panel 121. In other embodiments,the first panel and the second panel have similar widths. For example,the first panel 102 may have a first width 130 substantially equal to asecond width 132 of the second panel 121 (not shown). As used herein,widths are substantially equal when a difference between the widths isless than ten percent. In another embodiment, the first panel and thesecond panel have similar heights. For example, the first panel 102 hasa first height 126 substantially equal to a second height 128 of thesecond panel 121. As used herein, heights are substantially equal when adifference between the heights is less than ten percent. In variousembodiments, the first panel and the second panel have similar lengths.For example, the first panel 102 has a first length 122 substantiallyequal to a second length 124 of the second panel 121. As used herein,lengths are substantially equal when a difference between the lengths isless than ten percent. In other embodiments, the first panel and thesecond panel have different lengths.

As used herein the various panels, such as the first panel, the secondpanel, the third panel, etc., may include any number of sub-panels andmay be manufactured using various techniques. In one example, the firstpanel 102 is formed using a single sub-panel having the first cavity114, for example, using a molding process. In another example, the firstpanel 102 is formed by etching a first cavity 114 into a single planarsub-panel. As noted above, in some instances, a panel includes more thanone sub-panel. For example, the first panel 102 may be manufacturedusing a base sub-panel extending between the lower surface and a bottomsurface of the first cavity, and an outer sub-panel extending from thebase sub-panel. As such, the first panel 102 may be manufactured usingtwo planar sub-panels. In some instances, a panel may include a backside having a back cavity (see FIG. 11). In such instances, the firstpanel may include any number of sub-panels. For example, a backsub-panel and a front sub-panel may abut where the exposed side of theback sub-panel includes the back cavity and where the exposed side ofthe front sub-panel includes the first cavity. In other instances, thefirst panel may include more than two panels. For example, the firstpanel 102 may include a base sub-panel extending between a bottomsurface of the back cavity and a bottom surface of the first cavity, afront outer sub-panel extending from the base sub-panel, and a backouter sub-panel extending from the base sub-panel. As such, the firstpanel 102 may be manufactured using three planar sub-panels.

In some embodiments, the bus bar is approximately the size of thecavity. As used herein, a bus bar is approximately the size of a cavitywhen a difference in size between a bus bar and a cavity is less than 10percent, less than 5 percent, less than 1 percent, etc. Accordingly, thebus bar, when positioned within a cavity, may be aligned for aconnection. For example, the first bus bar 104 may be positioned tightlyinto the first cavity 114 to ensure a position for a connection with abattery module. As noted above, the first bus bar 104 may be rigid. Insuch instances, such a positioning of the first bus bar 104 may ensurethe connection without a flexibility of the first bus bar 104. In otherinstances, a connection element, such as a signal wire, may be flexible.Accordingly, a connection element may be smaller than a cavity to allowa movement in a first direction and/or a second direction. Such amovement may accommodate a connection. In certain embodiments, aconnection element is configured to move in a first direction. Forexample, the connection element may move parallel to the first width 130of the first panel 102 and/or the second width 132 of the second panel121. In some embodiments, a connection element is configured to move ina second direction. For example, the connection element may moveparallel to the first height 126 of the first panel 102 and/or to thesecond height 128 of the second panel 121. As shown in FIG. 3, the firstdirection and the second direction may be perpendicular. Moreover, invarious embodiments, a connection element is configured to move in athird direction. For example, the first bus bar 104 may move parallel tothe first length 122 of the first panel 102 and/or to the second length124 of the second panel 121. As shown in FIG. 3, the third direction maybe perpendicular to the first direction and the third direction may beperpendicular to the second direction.

In certain embodiments, the second panel may include an opening for acoupling element. For example, as shown in FIG. 3, the second panel 121may include opening 134 for a coupling element 136. In some embodiments,the coupling element extends outward from the first upper surface. Forexample, the coupling element 136 extends outward from the first uppersurface 110. Similarly, the second panel may include any number ofopenings for any number of coupling elements. For example, the secondpanel may include a second opening for a second coupling element of thefirst bus bar 104 and/or the second panel may include a third openingfor a third coupling element of the second bus bar 106. In anotherexample, the second panel includes no openings (see FIG. 6).

As noted above, in some instances, it is desirable for the cavity toposition the coupling element for a connection. In some embodiments, acavity may position a coupling element to align with an opening in asecond panel. For example, the first cavity 114 may position thecoupling element 136 to align with the opening 134 of the second panel121 (see FIGS. 1-5). In other embodiments, a cavity may position acoupling element to align with a back opening in a first panel. Forexample, a first cavity may position the back coupling element 208 toalign with the back opening 206 of the first panel 202 (see FIGS. 6-7).Similarly, in some embodiments, a cavity may position a coupling elementto align with a terminal. For example, the first cavity 114 may positionthe coupling element 136 to align with a first terminal. As discussedfurther, such a terminal may be positioned by a guide pin.

In certain embodiments, the second panel is in direct contact with thefirst panel. For example, the second panel 121 directly contacts thefirst panel 102 (see FIGS. 3-4). Moreover, in various embodiments, thesecond panel includes a second lower surface that directly contacts thefirst upper surface. For example, as shown in FIG. 5, the second panel121 includes a second lower surface 138 that directly contacts the firstupper surface 110.

In some instances, it is desirable to allow the coupling element to movein a direction normal to the first upper surface. For example, as shownin FIG. 5, the coupling element 136 is configured to move in a thirddirection 140 between the first upper surface 110 and the second lowersurface 138. In some embodiments, the third direction is perpendicularto the first direction and the third direction is perpendicular to thesecond direction.

In certain instances, it is desirable to provide a back opening in thefirst panel to simplify a manufacturing of the second panel. Forexample, as shown in FIG. 6, the backbone 200 includes first panel 202and a second panel 204. In some embodiments, the first panel 202 issubstantially similar to the first panel 102 except that the first panel102 further includes back opening 206. Similarly, in variousembodiments, the second panel 204 is similar to the second panel 121except that the second panel 204 omits the opening 134. Accordingly, asshown in FIG. 7, the back opening 206 may position the back couplingelement 208 similarly to the coupling element 136, thereby aligning theback coupling element 208 for a connection. Moreover, in someembodiments, the back coupling element extends outward from the firstlower surface. For example, the back coupling element 208 extendsoutward from the first upper surface.

FIG. 8 illustrates a battery system 400, in accordance to an exemplaryembodiment. The battery system 400 is suitable for a variety of fields,activities, and applications, including, but not limited to, hybridvehicles, electric vehicles, mining equipment, pumps, compressors, andthe like. For example, in some embodiments, the battery system 400contains 12 modules and 132 battery cells. Moreover, in the example, thebattery system 400 may output 480 volts.

In some embodiments, the battery system includes an interface panel. Forexample, as illustrated, the battery system 400 includes an interfacepanel 402 having a high voltage output 404. As used herein, a highvoltage exceeds an operating voltage of 50 volts. In some instances, ahigh voltage exceeds 120 volts, exceeds 240 volts, or exceeds 480 volts.As shown, in some embodiments, the interface panel 402 further includesa disconnect switch 406 to disconnect the high voltage output 404. Forexample, the disconnect switch 406 may be used to allow a replacement ofa battery cell of the battery system 400.

In some embodiments, it is desirable for the battery system to include abattery module to simplify a replacement of a battery cell. As shown inFIG. 9, the battery system 400 includes a battery module 408. FIG. 9illustrates two battery modules for illustration purposes only. Forexample, in some embodiments, the battery system 400 includes none, one,or more than two battery modules.

In some instances, the battery system includes a housing configured toreceive a battery module. For example, as shown in FIG. 9, the batterysystem 400 includes housing 412. Such a housing may be configured toreceive any number of battery modules. For example, as shown, thehousing 412 includes a bay 414. In other embodiments, the housing 412includes fewer than 12 bays (e.g., 2, 3, 4, 5, etc.), or more than 12bays (e.g., 13, 14, 15, etc.).

In various embodiments, the battery system includes a backbone system toelectronically connect battery modules to the battery system. Forexample, as shown in FIG. 9, battery system 400 includes a backbonesystem 416. As discussed further below, the backbone system 416 may beused to electronically connect battery modules using a bus bar system.

In some embodiments, the backbone system includes a coupling element tosafely connect a module to the backbone system. For example, as shown inFIG. 9, the backbone system 416 includes a coupling element 418. Asdiscussed further below, the coupling element 418 may be configured tobe electronically insulated when disconnected from a battery module(e.g., 408) in order to provide improved safety.

In some embodiments, the housing includes guide pins to guideconnections of the battery modules and to protect connections of thebattery modules. For example, as shown in FIG. 9, the housing 412includes guide pin 420. As discussed further below, the guide pin may beused to guide a battery module into a bay of the housing and may be usedto bear weight of the module in order to protect a coupling element.

FIGS. 10-18 illustrate a backbone system 500, in accordance to anexemplary embodiment. In some embodiments, the backbone system 500 issimilar to the backbone system 416 of FIG. 9 and/or the backbone system100 of FIGS. 1-5. For example, the backbone system 500 may be configuredfor the housing 412 and the battery module 408. In other embodiments,the backbone system 500 is different than the backbone system 416 and/orthe backbone system 100.

In some embodiments, the backbone system 500 includes a bus bar systemfor electronically connecting battery modules (e.g., 408). For example,as shown in FIG. 10, the backbone system 500 includes a bus bar system502. The bus bar system may include any number of bus bars. For example,as shown in FIGS. 13-14 the bus bar system 502 may include eight busbars. In other embodiments, the bus bar system 502 includes fewer busbars (e.g., 2, 3, 4, etc.) and more bus bars (e.g., 9, 10, 11, etc.).

In various embodiments, the backbone system includes a first panel forelectronically insulating the bus bar system. For example, as shown inFIG. 10, the backbone system 500 includes a first panel 512. In someembodiments, the first panel 512 is an electric insulator. In suchembodiments, the first panel may electronically insulates one or moreportions of the bus bar system. In various embodiments, the first panelincludes one or more through holes. For example, the first panel 512 mayinclude a through hole for a signal connector, a guide pin, a couplingelement, a bolt, and the like. In some embodiments, the first panelincludes one or more blind holes. For example, the first panel 512 mayinclude a blind hole for a routing a signal cable.

In some embodiments, the backbone system includes a second panel forelectronically insulating the bus bar system. For example, as shown inFIG. 10, the backbone system 500 includes a second panel 506. In someembodiments, the second panel 506 is an electric insulator. In suchembodiments, the second panel may electronically insulate the bus barsystem. In various embodiments, the third panel includes one or morethrough holes. For example, the second panel 506 may include a throughhole for a signal connector, a guide pin, a coupling element, a bolt,and the like. In some embodiments, the second panel includes one or moreblind holes. For example, the second panel 506 may include a blind holefor a routing a signal cable. Moreover, in varying embodiments, thesecond panel has one or more grooves for coupling with a housing. Forexample, the second panel 506 includes a groove (not shown). In otherembodiments, the second panel omits the grooves for coupling with ahousing. For example, the second panel 506 has an outer surface that issubstantially planar (see FIGS. 25-26).

In some embodiments, the backbone system includes a third panel forelectronically insulating the bus bar system. For example, as shown inFIG. 10, the backbone system 500 includes a third panel 504. In someembodiments, the third panel 504 is an electric insulator. In suchembodiments, the third panel may electronically insulate the bus barsystem. In various embodiments, the third panel includes one or morethrough holes. For example, the third panel 504 may include a throughhole for a signal connector, a guide pin, a coupling element, a bolt,and the like. In some embodiments, the third panel includes one or moreblind holes. For example, the third panel 504 may include a blind holefor a routing a signal cable. Moreover, in varying embodiments, thethird panel has one or more grooves for coupling with a housing. Forexample, the third panel 504 includes a groove 544. In otherembodiments, the third panel omits the grooves for coupling with ahousing. For example, the third panel 504 has an outer surface that issubstantially planar (see FIGS. 25-26).

In various embodiments, the first panel and the second panelsubstantially encapsulate the bus bar system and/or one or more bus barsof the bus bar system. As used herein, an object is substantiallyencapsulated when at least eighty percent of a surface area of theobject is covered. For example, as shown in FIGS. 13-14, the first panel512 and the second panel 506 substantially encapsulate the first bus bar536 when the first panel 512 and the second panel 506 cover first busbar 536 (See FIGS. 13-14). Similarly, in some embodiments, the firstpanel and the third panel substantially encapsulate the bus bar systemand/or one or more bus bars of the bus bar system. For example, as shownin FIGS. 13-14, the first panel 512 and the third panel 504substantially encapsulate the second back bus bar 538 when the firstpanel 512 and the third panel 504 cover more than eighty percent of asurface area of the second back bus bar 538. Further, in certainembodiments, the second panel and the third panel substantiallyencapsulate the bus bar system. For example, as shown, the second panel506 and the third panel 504 substantially encapsulate the bus bar system502 by covering more than eighty percent of a surface area of bus barsof the bus bar system 502.

In one embodiment, the second panel and the third panel are on oppositesides of the bus bar system. For example, as shown, the second panel 506is on a first upper surface 510 of the bus bar system 502. Similarly,the third panel 504 is on a first lower surface 508 of the bus barsystem 502. In the example, the first lower surface 508 and the firstupper surface 510 are on opposite sides of the bus bar system 502. Asused herein, opposite sides are sides that face in substantiallyopposing directions. For example, the first lower surface 508 faces inone direction along the axis 514 and the first upper surface 510 facesin the other direction along the axis 514. Similarly, the first paneland the second panel may be on opposite sides of the third panel. Forexample, as shown, the third panel 504 is on the first lower surface 508of the first panel 512. In another example, as shown, the second panel506 is on the first upper surface 510 of the first panel 512.

In certain embodiments, the backbone system includes a guide pin forfacilitating a connection with a battery module. For example, as shownin FIG. 11, the backbone system 500 includes a guide pin 542. Thebackbone system 500 may include any number of guide pins, and, in someembodiments, the guide pin 542 may be representative of other guide pinsof the backbone system 500. In certain embodiments, the guide pin isinserted through the first panel. For example, as shown in FIG. 11, theguide pin 542 is inserted through the first panel 512. Similarly, invarying embodiments, the guide pin is inserted through the second paneland/or the third panel. For example, the guide pin 542 may be insertedthrough the second panel 506 and/or through the third panel 504.Moreover, in some embodiments, the guide pin extends away from thesecond panel and/or the guide pin extends away from the third panel. Forexample, the guide pin 542 may extend away from the second panel 506. Inanother example, the guide pin 542 may extend away from the third panel504. Accordingly, the guide pin may extend into a bay to facilitate aconnection with a battery module (see FIGS. 22-23).

In various embodiments, the first panel includes a first socket tofacilitate an attachment of a first coupling element. For example, asshown in FIG. 11, the first panel 512 of the backbone system 500includes a first socket 524 for a first coupling element 526. The firstsocket 524 and the first coupling element 526 may have a substantiallyequal size and/or shape to position the first coupling element 526 onthe first panel 512 for a connection.

In some embodiments, the first panel includes a second socket tofacilitate an attachment of a second coupling element. For example, asshown in FIG. 11, the first panel 512 includes a second socket 546 for asecond coupling element 548. The second socket 546 and the secondcoupling element 548 may have a substantially equal size and/or shape toposition the second coupling element 548 on the first panel 512 for aconnection.

In certain embodiments, the first panel includes a third socket tofacilitate an attachment of a third coupling element. For example, asshown in FIG. 11, the first panel 512 includes a third socket 516 for athird coupling element 518. The third socket 516 and the third couplingelement 518 may have a substantially equal size and/or shape to positionthe third coupling element 518 on the first panel 512 for a connection.

In some embodiments, the first panel includes a first back socket tofacilitate an attachment of a first back coupling element. For example,as shown in FIG. 11, the first panel 512 includes a first back socket520 for a first back coupling element 522. The first back socket 520 andthe first back coupling element 522 may have a substantially equal sizeand/or shape to position the first back coupling element 522 on thefirst panel 512 for a connection.

In some embodiments, the first panel includes a second back socket tofacilitate an attachment of a second back coupling element. For example,as shown in FIG. 11, the first panel 512 includes a second back socket528 for a second back coupling element 530. The second back socket 528and the second back coupling element 530 may have a substantially equalsize and/or shape to position the second back coupling element 530 onthe first panel 512 for a connection.

In various embodiments, the bus bar system includes a first bus bar. Forexample, as shown in FIG. 11, the bus bar system 502 includes a firstbus bar 536. In certain embodiments, the first bus bar may be positionedbetween the first panel and the second panel. For example, as shown inFIGS. 10-11, the first bus bar 536 may be positioned between the firstpanel 512 and the second panel 506. Moreover, in some embodiments, thefirst bus bar is electronically coupled to the first coupling element.For example, as shown, the first bus bar 536 is mechanically attached tothe first coupling element 526. Further, in some embodiments, the firstbus bar is electronically coupled to the second coupling element. Forexample, as shown, the first bus bar 536 is mechanically attached to thesecond coupling element 548.

In certain embodiments, the first panel includes a first cavity for thefirst bus bar. For example, as shown in FIG. 13, the first panel 512includes a first cavity 550 for the first bus bar 536. In someembodiments, the first cavity 550 is similar to the first cavity 114 ofFIG. 1. For example, the first bus bar 536 may be positioned tightlyinto the first cavity 550 to ensure a position on the first panel 512for a connection with a battery module. In other embodiments, the firstcavity 550 and the first cavity 114 are different.

In some embodiments, the bus bar system includes a second bus bar. Forexample, as shown in FIG. 11, the bus bar system 502 includes a secondbus bar 532. In certain embodiments, the second bus bar may bepositioned between the first panel and the second panel. For example, asshown in FIGS. 10-11, the second bus bar 532 may be positioned betweenthe first panel 512 and the second panel 506. Moreover, in someembodiments, the second bus bar is electronically coupled to the secondcoupling element. For example, as shown, the second bus bar 532 ismechanically attached to the third coupling element 518. Further, insome embodiments, the second bus bar is mechanically separated from thefirst bus bar. For example, as shown, the second bus bar 532 is spacedfrom the first bus bar 536.

In certain embodiments, the first panel includes a second cavity for thesecond bus bar. For example, as shown in FIG. 13, the first panel 512includes a second cavity 552 for the second bus bar 532. In someembodiments, the second cavity 552 is similar to the second cavity 118of FIG. 1. For example, the second bus bar 532 may be positioned tightlyinto the second cavity 552 to ensure a position on the first panel 512for a connection with a battery module. In other embodiments, the secondcavity 552 and the second cavity 118 are different. Moreover, in someembodiments, the first cavity is spaced from the second cavity. Forexample, as shown in FIG. 12, the first cavity 550 is spaced from thesecond cavity 552 such that the first bus bar 536 and the second bus bar532 are prevented from physically contacting.

In various embodiments, the bus bar system includes a first back busbar. For example, as shown in FIG. 11, the bus bar system 502 includes afirst back bus bar 534. In certain embodiments, the first back bus barmay be positioned between the first panel and the third panel. Forexample, as shown in FIGS. 10-11, the first back bus bar 534 may bepositioned between the first panel 512 and the third panel 504.Moreover, in some embodiments, the first back bus bar is electronicallycoupled to the first back coupling element. For example, as shown, thefirst back bus bar 534 is mechanically attached to the first backcoupling element 522. Further, in some embodiments, the first back busbar is mechanically separated from the first bus bar and the second busbar. For example, as shown, the first back bus bar 534 is spaced fromthe first bus bar 536 and the second bus bar 532.

In certain embodiments, the first panel includes a first back cavity forthe first back bus bar. For example, as shown in FIG. 11, the firstpanel 512 includes a first back cavity 554 for the first back bus bar534. In some embodiments, the first back cavity 554 is similar to thefirst cavity 114 of FIG. 1. For example, the first back bus bar 534 maybe positioned tightly into the first back cavity 554 to ensure aposition on the first panel 512 for a connection with a battery module.In other embodiments, the first back cavity 554 and the first cavity 114are different. For example, the first back cavity 554 and the firstcavity 114 may have a different size and/or shape. Moreover, in someembodiments, the first back cavity is spaced from the first cavityand/or the second cavity. For example, as shown in FIGS. 11-12, thefirst back cavity 554 is spaced from the first cavity 550 and secondcavity 552 such that the first back bus bar 534 is prevented fromphysically contacting the first bus bar 536 and the second bus bar 532.

In some embodiments, the bus bar system includes a second back bus bar.For example, as shown in FIG. 11, the bus bar system 502 includes asecond back bus bar 538. In certain embodiments, the second back bus barmay be positioned between the first panel and the third panel. Forexample, as shown in FIGS. 10-11, the second back bus bar 538 may bepositioned between the first panel 512 and the third panel 504.Moreover, in some embodiments, the second back bus bar is electronicallycoupled to the second back coupling element. For example, as shown, thesecond back bus bar 538 is mechanically attached to the second backcoupling element 530. Further, in some embodiments, the second back busbar is mechanically separated from the first bus bar, the second busbar, and the first back bus bar. For example, as shown, the second backbus bar 538 is spaced from the first bus bar 536, the second bus bar532, and the first back bus bar 534.

In certain embodiments, the first panel includes a second back cavityfor the second back bus bar. For example, as shown in FIG. 11, the firstpanel 512 includes a second back cavity 556 for the second back bus bar538. In some embodiments, the second back cavity 556 is similar to thesecond cavity 118 of FIG. 1. For example, the second back bus bar 538may be positioned tightly into the second back cavity 556 to ensure aposition for a connection with a battery module. In other embodiments,the second back cavity 556 and the second cavity 119 are different.Moreover, in some embodiments, the second back cavity is spaced from oneor more of the first back cavity, the first cavity and the secondcavity. For example, as shown in FIGS. 11-12, the second back cavity 554is spaced from the first back cavity 554, the first cavity 550, andsecond cavity 552 such that the second back bus bar 538 is preventedfrom physically contacting first back bus bar 534, the first bus bar536, and the second bus bar 532.

In some instances, a link may be used to connect one side of bus barswith another side of bus bars. For example, a link 540 may mechanicallyand electronically couple with the second bus bar 532. Similarly, thelink 540 may mechanically and electronically couple with the first backbus bar 534. Moreover, as shown in FIG. 11, the link may be positionedwithin a hole extending from a first lower surface to a first uppersurface. The hole may, in some embodiments, position the link 540 on thefirst panel 512. In some embodiments, the second cavity positions thesecond bus bar to align with the link. For example, the second cavity552 positions the second bus bar 532 to align with the link 540. Incertain embodiments, the first back cavity 554 positions the first backbus bar 534 to align with the link 540.

In various instances, a battery system utilizes a battery module havinga set of batteries to allow simplified replacement of a battery cell ofthe battery system. A set of batteries can include any type and numberof batteries. For example, as shown in FIGS. 19-21, the battery module700 includes a set 702 of twelve battery cells. In other embodiments,the set includes less than nine battery cells (e.g., 2, 3, 6, etc.) andmore than nine batteries (e.g., 10, 11, 12, etc.). As used herein, abattery cell may include any number of sub-cells using variousconnection schemes. For example, a battery cell may include any numberof sub-cells connected in series and/or any number of sub-cellsconnected in parallel.

In some embodiments, the set of batteries includes a first battery cell.For example, the set 702 includes a first battery cell 704. The firstbattery cell may include any device that can store energy, particularlydevices that convert stored chemical energy into electrical energy.Examples of a battery cell include capacitors, ultra-capacitors, andelectrochemical cells. Examples of electrochemical cells include primary(e.g., single use) and secondary (e.g., rechargeable). Examples ofsecondary electrochemical cells include lead-acid, valve regulatedlead-acid (VRLA), gel, absorbed glass mat (AGM), nickel-cadmium (NiCd),nickel-zinc (NiZn), nickel metal hydride(NiMH), lithium-ion (Li-ion),and the like. The first battery cell may have various voltage levels.For example, the first battery cell 704 may have a voltage of less than40 volts, less than 20 volts, less than 10 volts, less than 5 volts, 3.3volts, less than 3.3 volts, etc. Similarly, the first battery cell mayhave various energy capacity levels. For example, the first battery 704may have a capacity of 13 ampere-hour, more than 10 ampere-hour, morethan 20 ampere-hour, more than 25 ampere-hour, etc.

In certain embodiments, the battery module includes a first terminal tocouple with a coupling element. For example, as shown in FIG. 20, thebattery module 700 includes a first terminal 718 (e.g., positive) tocouple with a first coupling element. Similarly, in some embodiments thebattery module includes a second terminal to couple with a couplingelement. For example, as shown in FIG. 20, the battery module 700includes a second terminal 720 (e.g., negative) to couple with a secondcoupling element.

In some embodiments, a first battery cell of the set of battery cellsincludes a first terminal and a second terminal. For example, as shownin FIG. 21, the first battery cell 704 of the set 702 includes a firstbattery 706 (e.g., positive) and a second terminal 708 (e.g., negative).Similarly, in certain embodiments, a second battery cell of the set ofbatteries includes a third terminal (e.g., positive) and a fourthterminal (e.g., negative). For example, as shown in FIG. 21, the secondbattery cell 710 of the set 702 includes a third terminal 712 and afourth terminal 714.

In certain embodiments, the set of battery cells is serially connectedto increase a voltage across the first terminal and the second terminal.For example, as shown in FIG. 21, the connection path 722 extends from anegative side to a high side of each battery cell of the set 702. In theexample, one side of the connection path 722 is connected to the firstterminal 718 and the other side of the connection path 722 is connectedto the second terminal 720. Moreover, in various embodiments, the set702 is serially connected to output 40 volts across the first terminaland the second terminal. For example, each battery cell of the set 702has a voltage of 3.3 volts. Accordingly, in the example, the serialconnection of the set 702, results in a voltage of approximately 40volts across the first terminal 718 and the second terminal 720.

FIG. 22 illustrates a battery system, in accordance with an exemplaryembodiment. In some embodiments, the battery system 800 is similar tothe battery system 400 of FIGS. 8-11. For example, the battery systemmay accommodate twelve battery modules. In other embodiments, thebattery system 800 is different than the battery system 400.

In one embodiment, the battery system includes a housing. For example,as shown in FIG. 22, the battery system 800 includes a housing 802. Thehousing may be formed of various materials, for example, steel,aluminum, etc.

In some embodiments, the housing supports an upper backbone. Forexample, as shown in FIG. 22, the housing 802 supports an upper backbone804. In some embodiments, the upper backbone 804 is similar to one ormore of the backbone system 416 of FIG. 9, the backbone system 100 ofFIGS. 1-5, and the backbone system 500 of FIGS. 10-18. For example, theupper backbone 804 may be configured for the battery module 408. Inother embodiments, the upper backbone 804 is different than one or moreof the backbone system 416, the backbone system 100, and the backbonesystem 500.

In various embodiments, the housing supports a lower backbone. Forexample, as shown in FIG. 22, the housing 802 supports a lower backbone806. In some embodiments, the lower backbone 806 is similar to one ormore of the backbone system 416 of FIG. 9, the backbone system 100 ofFIGS. 1-5, and the backbone system 500 of FIGS. 13-21. For example, thelower backbone 806 may be configured for the battery module 408. Inother embodiments, the lower backbone 806 is different than one or moreof the backbone system 416, the backbone system 100, and the backbonesystem 500.

In certain embodiments, the housing includes any number of bays tofacilitate a connection of the upper backbone with any number ofmodules. For example, as shown in FIG. 22, the housing 802 includes afirst bay 808 for connections with the upper backbone 804. Similarly, insome embodiments, the housing may include a second bay. For example, asshown in FIG. 22, the housing 802 includes a second bay 854 forconnections with the upper backbone 804. In some embodiments, thehousing includes a first back bay. For example, as shown in FIG. 23, thehousing 802 includes a first back bay 810 for connections with the upperbackbone 804. Similarly, the housing may include a second back bay.

In some embodiments, the housing includes any number of bays tofacilitate a connection with any number of backbones of the batterysystem. For example, as shown in FIG. 22, the housing 802 includes afirst lower bay 812 for connections with the lower backbone 806.Similarly, in some embodiments, the housing may include a first lowerback bay. For example, as shown in FIG. 23, the housing 802 includes afirst lower back bay 814 for connections with the lower backbone 806.

In some embodiments, one or more of the first bay, the second bay, thefirst back bay, second back bay, first lower bay, and the first lowerback bay may be similar. For example, the first bay 808, the second bay854, the first back bay 810, the first lower bay 812, and the firstlower back bay 814 may have similar physical dimensions such as height,width, and depth. In other embodiments, one or more of the first bay,the second bay, the third bay, and the fourth bay are different.

In various embodiments, the first bay and the first back bay are onopposite sides of the upper backbone. For example, as shown in FIGS.22-23, the first bay 808 and the first back bay 810 are on oppositesides of the upper backbone 804. In one embodiment, the first bay is ona first side of the upper backbone. For example, as shown in FIG. 22,the first bay 808 is on a first side 836 of the upper backbone 804. Insome embodiments, the second bay is on a second side of the upperbackbone. For example, as shown in FIG. 23, the first back bay 810 is ona second side 838 of the upper backbone 804. In various embodiments, thefirst side and the second side are on opposite sides of the upperbackbone. For example, as shown in FIGS. 22-23, the first side 836 andthe second side 838 are on opposite sides of the upper backbone 804.

Similarly, in some embodiments, the first lower bay and the first lowerback bay are on opposite sides of the lower backbone. For example, asshown in FIGS. 22-23, the first lower bay 812 and the first lower backbay 814 are on opposite sides of the lower backbone 806. In oneembodiment, the first lower bay is on a third side of the lowerbackbone. For example, as shown in FIG. 22, the first lower bay 812 ison a third side 840 of the lower backbone 806. In some embodiments, thefirst lower back bay is on a fourth side of the lower backbone. Forexample, as shown in FIG. 23, the first lower back bay 814 is on afourth side 842 of the lower backbone 806. In various embodiments, thethird side and the fourth side are on opposite sides of the lowerbackbone. For example, as shown in FIGS. 22-23, the third side 840 andthe fourth side 842 are on opposite sides of the lower backbone 806.

In various embodiments, the first side and the third side aresubstantially aligned. For example, as shown in FIG. 22, the first side836 and the second side 838 are substantially aligned. In oneembodiment, sides are substantially aligned when a plane formed by asurface of the one side and a plane formed by the other side areparallel. In some embodiments, sides are substantially aligned when aplane formed by a surface of the one side and a plane formed by theother side are parallel and are separated by a distance of less than athickness of either the plane. Similarly, in certain embodiments, thesecond side and the fourth side are substantially aligned. For example,as shown in FIG. 23, the second side 838 and the fourth side 842 aresubstantially aligned.

In certain embodiments, the upper backbone includes a first couplingelement. For example, as shown in FIG. 22, the upper backbone 804includes a first coupling element 820. In one embodiment, the firstcoupling element 820 is coupled to a first bus bar (e.g., first bus bar536 of FIG. 11) of the upper backbone 804 (not shown). Similarly, insome embodiments, the upper backbone includes a second coupling element.For example, as shown in FIG. 22, the upper backbone 804 includes asecond coupling element 850. In various embodiments, the upper backboneincludes a third coupling element. For example, as shown in FIG. 22, theupper backbone 804 includes a third coupling element 816. In oneembodiment, the third coupling element 816 is coupled to a second busbar (e.g., second bus bar 532 of FIG. 11) of the upper backbone 804 (notshown).

In certain embodiments, the upper backbone includes a first backcoupling element. For example, as shown in FIG. 23, the upper backbone804 includes a first back coupling element 818. In one embodiment, thefirst back coupling element 818 is coupled to a first back bus bar(e.g., first back bus bar 534 of FIG. 11) of the upper backbone 804 (notshown). In some embodiments, the upper backbone includes a second backcoupling element. For example, as shown in FIG. 23, the upper backbone804 includes a second back coupling element 822. In one embodiment, thesecond back coupling element 822 is coupled to a second back bus bar(e.g., second back bus bar 538 of FIG. 11) of the upper backbone 804(not shown).

In various embodiments, the lower backbone includes coupling elementssubstantially similar to the upper backbone. For example, as shown inFIG. 22, the lower backbone 806 includes a first lower coupling element824. In another example, as shown in FIG. 23, the lower backbone 806includes a first lower back coupling element 826. In other embodiments,the lower backbone and the upper backbone are different.

In certain embodiments, the first bay includes a first guide pin. Forexample, as shown in FIG. 22, the first bay 808 includes a first guidepin 828. In some embodiments, the first guide pin is configured to guideeach of a plurality of battery modules into the first bay. For example,the first guide pin 828 may be positioned vertically and horizontallywithin the first bay 808 to align with the plurality of battery modules.Similarly, in various embodiments, the second bay includes a secondguide pin. For example, as shown in FIG. 22, the second bay 854 includesa second guide pin 852. In some embodiments, the second guide pin isconfigured to guide each of the plurality of battery modules into thesecond bay. For example, the second guide pin 852 may be positionedvertically and horizontally within the second bay 854 to align with theplurality of battery modules.

In some embodiments, the first back bay includes a first back guide pin.For example, as shown in FIG. 23, the first back bay 810 includes afirst back guide pin 830. In some embodiments, the first back guide pinis configured to guide each of the plurality of battery modules into thefirst back bay. For example, the first back guide pin 830 may bepositioned vertically and horizontally within the first back bay 810 toalign a coupling element with a terminal of a battery module of theplurality of battery modules.

In some embodiments, the first lower bay includes a first lower guidepin. For example, as shown in FIG. 22, the first lower bay 812 includesa first lower guide pin 832. In some embodiments, the first lower guidepin is configured to guide each of the plurality of battery modules intothe first lower bay. For example, the first lower guide pin 832 may bepositioned vertically and horizontally within the first lower bay 812 toalign a coupling element with a terminal of a battery module of theplurality of battery modules. Similarly, in various embodiments, thefirst lower back bay includes a first lower back guide pin. For example,as shown in FIG. 23, the first lower back bay 814 includes a first lowerback guide pin 834. In some embodiments, the first lower back guide pinis configured to guide each of the plurality of battery modules into thefirst lower back bay. For example, the first lower back guide pin 834may be positioned vertically and horizontally within the first lowerback bay 814 to align with the plurality of battery modules.

In some instances, a backbone system may facilitate a connection ofbattery modules for increasing a voltage of a battery system. Forexample, as shown in FIG. 24, the battery system 900 includes a lowerbackbone 902 and an upper backbone 904. An electrical series connectionpath 908 indicates a connection to battery module 906 that allows twelve40 volt batteries to output 480 volts across the negative systemterminal 910 and the positive system terminal 912. In other embodiments,the battery system 900 may be configured for any output voltage level,any battery cell type (e.g., voltage), any number of backbones (e.g., 1,3, 4, etc.), and the like. Accordingly, the battery system 900 mayfacilitate a connection of battery module 906 for increasing a voltageof a battery system 900 by using an electrical series connection path908.

In various embodiments, the lower backbone 902 and/or the upper backbone904 can allow connection with any number of modules (e.g., see FIGS.31-34). As shown, the lower backbone 902 may connect six battery modulesincluding the battery module 906. Similarly, as shown, the upperbackbone 904 may connect six battery modules. Further, in the example,the battery module 906 is exemplary to the battery modules connected tothe lower backbone 902 and the upper backbone 904. In other embodiments,the lower backbone 902 connects one or more battery modules differentfrom the battery module 906 and/or the upper backbone 904 connects oneor more battery modules different from the battery module 906.

FIGS. 25-26 illustrate another backbone system 1000, in accordance to anexemplary embodiment. In some embodiments, the backbone system 1000 issimilar to the backbone system 416 of FIG. 9. For example, the backbonesystem 1000 may be configured for the housing 412 and the battery module408. In other embodiments, the backbone system 1000 is different thanthe backbone system 416.

In some embodiments, the backbone system may have a first side and asecond side to facilitate a placement of the battery modules on oppositesides of the backbone system. For example, as shown in FIGS. 25-26, thebackbone system 1000 includes a first side 1002 having a couplingelement 1004 and a second side 1006 having a back coupling element 1008.Accordingly, the backbone system may allow for battery modules to beplaced on both sides of the backbone (e.g., see FIG. 9). The backbonesystem 1000 may include additional components, for example, couplingelements, signal connectors, through holes, blind holes, etc.

In some embodiments, a battery system may be configured to allow removalof a battery module by pulling the battery module. For example, asillustrated in FIG. 27, a battery system 1100 allows a technician 1102to remove the battery module 1104 by a pull force 1106. In someembodiments, an electrical output of the battery system 1100 is isolatedprior to the removal of the battery module 1104 to prevent harm to thetechnician 1102 and/or to protect the battery system 1100.

In some embodiments, the battery system 1100 is similar to the batterysystem 400 of FIGS. 8-9 and/or the battery system 800 of FIGS. 22-23.For example, the battery system may contain any number of battery cellsand the battery system 1100 may output any voltage. In otherembodiments, the battery system 1100 is different than the batterysystem 400 and/or the battery system 800.

In various embodiments, the battery module 1104 is substantially similarto the battery module 700. For example, the battery module 1104 includesa first terminal similar to the first terminal 718. In another example,the battery module 1104 includes a second terminal similar to the secondterminal 720. In a further example, the battery module 1104 includes aset having a first battery cell and a second battery cell similar to theset 702 having a first battery cell 704 and a second battery cell 710.In other embodiments, the battery module 1104 is different than thebattery module 700.

In certain embodiments, a battery system may be configured to allowinsertion of a battery module by pushing the battery module into thebattery system. For example, as illustrated in FIG. 28, the batterysystem 1100 allows a technician 1102 to insert a new battery module 1108by a push force 1110. In some embodiments, the new battery module 1108is substantially similar to the battery module 1104. For example, thenew battery module 1108 and the battery module 1104 may have a samevoltage level. In another example, the new battery module 1108 has asame maximum design capacity level as the battery module 1104. In yetanother example, the new battery module 1108 has a same type and numberof battery cells as the battery module 1104. In one example, the newbattery module 1108 has a same charge level as the battery module 1104.In other embodiments, the new battery module 1108 and the battery module1104 are different.

FIGS. 31-34 illustrate various connection schemes. As previously noted,the embodiments may use any number of battery modules, backbones,voltages, technologies, etc. Accordingly, the exemplary battery systemsillustrated in FIGS. 31-34 are non-limiting examples.

In some embodiments, a battery system may use two backbones to connecttwelve battery modules. For example, FIG. 31 illustrates a batterysystem 1200 having a first backbone 1201 and a second backbone 1203. Asshown, the first backbone 1201 connects a first battery module 1202, asecond battery module 1204, and a third battery module 1206 on one side.Additionally, the first backbone 1201 connects a fourth battery module1208, a fifth battery module 1210, and a sixth battery module 1212 onthe other side. Similarly, as shown, the second backbone 1203 connects aseventh battery module 1214, an eighth battery module 1216, and a ninthbattery module 1218 on one side. Additionally, the second backbone 1203connects a tenth battery module 1220, an eleventh battery module 1222,and a twelfth battery module 1224 on the other side.

In some embodiments, a battery system may use three backbones to connectsixteen battery modules. For example, FIG. 32 illustrates a batterysystem 1300 having a first backbone 1301, a second backbone 1303, and athird backbone 1305. As shown, the first backbone 1301 connects a firstbattery module 1302, a second battery module 1304, and a third batterymodule 1306 on one side. Additionally, the first backbone 1301 connectsa fourth battery module 1308, a fifth battery module 1310, and a sixthbattery module 1312 on the other side. Similarly, as shown, the secondbackbone 1303 connects a seventh battery module 1314, an eighth batterymodule 1316, and a ninth battery module 1318 on one side. Additionally,the second backbone 1303 connects a tenth battery module 1320, aneleventh battery module 1322, and a twelfth battery module 1324 on theother side. Further, as shown, the third backbone 1305 connects athirteenth battery module 1326 and a fourteenth battery module 1328 onone side. Additionally, the third backbone 1305 connects a fifteenthbattery module 1330 and a sixteenth battery module 1332 on the otherside.

In certain embodiments, a battery system may use two backbones toconnect sixteen battery modules. For example, FIG. 33 illustrates abattery system 1400 having a first backbone 1401 and a second backbone1403. As shown, the first backbone 1401 connects a first battery module1402, a second battery module 1404, a third battery module 1406, and afourth battery module 1408 on one side. Additionally, the first backbone1401 connects a fifth battery module 1410, a sixth battery module 1412,a seventh battery module 1414, and an eighth battery module 1416 on theother side. Similarly, as shown, the second backbone 1403 connects aninth battery module 1418, a tenth battery module 1420, an eleventhbattery module 1422, and a twelfth battery module 1424 on one side.Additionally, the second backbone 1403 connects a thirteenth batterymodule 1426, a fourteenth battery module 1428, a fifteenth batterymodule 1430, and a sixteenth battery module 1432 on the other side.

In various embodiments, a battery system may use two backbones toconnect eight battery modules. For example, FIG. 34 illustrates abattery system 1500 having a first backbone 1501 and a second backbone1503. As shown, the first backbone 1501 connects a first battery module1502 and a second battery module 1504 on one side. Additionally, thefirst backbone 1501 connects a third battery module 1506 and a fourthbattery module 1508 on the other side. Similarly, as shown, the secondbackbone 1503 connects a fifth battery module 1510 and a sixth batterymodule 1512 on one side. Additionally, the second backbone 1503 connectsa seventh battery module 1514 and an eighth battery module 1516 on theother side.

While various embodiments of the invention have been described, thedescription is intended to be exemplary, rather than limiting and itwill be apparent to those of ordinary skill in the art that many moreembodiments and implementations are possible that are within the scopeof the invention. Accordingly, the invention is not to be restrictedexcept in light of the attached claims and their equivalents. Also,various modifications and changes may be made within the scope of theattached claims.

We claim:
 1. An apparatus comprising: a first panel including an firstupper surface and a first lower surface; wherein the first upper surfaceincludes a first cavity extending into the first upper surface towardsthe first lower surface; a first bus bar within the first cavity; asecond panel having a second lower surface in direct contact with thefirst upper surface; and wherein the second lower surface extends over asubstantial portion of the first cavity.
 2. The apparatus according toclaim 1, wherein the first cavity includes an inner surface; and whereinthe first bus bar is contained within the inner surface.
 3. Theapparatus according to claim 1, wherein the first bus bar and the firstcavity are approximately equal in size.
 4. The apparatus according toclaim 1, wherein the first bus bar includes a coupling element extendingoutward from the first upper surface; wherein the second panel includesan opening; wherein the coupling element extends through the opening;and wherein the first cavity positions the coupling element to alignwith the opening.
 5. The apparatus according to claim 1, wherein thefirst bus bar includes a back coupling element extending outward fromthe first lower surface; wherein the first cavity includes a backopening, the back opening extending from the first upper surface to thefirst lower surface; wherein the back coupling element extends throughthe back opening; and wherein the first cavity positions the backcoupling element to align with the back opening.
 6. The apparatusaccording to claim 1, further comprising: wherein the first uppersurface includes a second cavity extending into the first upper surfacetowards the first lower surface; a second bus bar within the secondcavity; and wherein the first bus bar is spaced from the second bus bar.7. An apparatus comprising: a first panel, the first panel including anfirst upper surface and a first lower surface; wherein the first uppersurface includes a first cavity extending into the first upper surfacetowards the first lower surface and wherein the first upper surfaceincludes a second cavity extending into the first upper surface towardsthe first lower surface; wherein the first cavity is spaced from thesecond cavity; a first bus bar within the first cavity; a second bus barwithin the second cavity; a second panel having a second lower surfacein direct contact with the first upper surface; and wherein the secondlower surface extends over a substantial portion of the first cavity andwherein the second lower surface extends over a substantial portion ofthe second cavity.
 8. The apparatus according to claim 7, furthercomprising: wherein the first bus bar includes a first coupling elementand wherein the first bus bar includes a second coupling element; afirst terminal of a first battery module, the first terminal beingmechanically coupled to the first coupling element; and wherein thefirst cavity positions the first coupling element to align with thefirst terminal.
 9. The apparatus according to claim 8, furthercomprising: wherein the second bus bar includes a third couplingelement; a second terminal of the first battery module, the secondterminal being mechanically coupled to the third coupling element;wherein the second cavity positions the third coupling element to alignwith the second terminal; and wherein the first terminal is spaced fromthe second terminal.
 10. The apparatus according to claim 9, furthercomprising: wherein the first lower surface includes a first back cavityextending into the first lower surface towards the first upper surface;wherein the first back cavity is spaced from the first cavity andwherein the first back cavity is spaced from the second cavity; a firstback bus bar within the first back cavity; a third panel having a thirdupper surface into direct contact with the first lower surface; andwherein the third upper surface extends over a substantial portion ofthe first back cavity.
 11. The apparatus according to claim 10, furthercomprising: wherein the first panel includes a hole extending from thefirst lower surface to the first upper surface; a link positioned withinthe hole, the link being mechanically coupled to the second bus bar andthe link being mechanically coupled to the first back bus bar; whereinthe second cavity positions the second bus bar to align with the link;and wherein the first back cavity positions the first back bus bar toalign with the link.
 12. The apparatus according to claim 10, whereinthe first back bus bar includes a first back coupling element andwherein the first back bus bar includes a second back coupling element;a first back terminal of a second battery module, the first backterminal being mechanically coupled to the first back coupling element;wherein the first back cavity positions the first back coupling elementto align with the first back terminal; and wherein the first batterymodule and the first back battery module are positioned on oppositesides of the first panel.
 13. The apparatus according to claim 10,wherein the first panel, the second panel, and the third panel havesubstantially similar heights; and wherein the first panel, the secondpanel; and the third panel have substantially similar lengths.
 14. Theapparatus according to claim 7, wherein the first bus bar has a shapecorresponding with a shape of the first cavity; and wherein the secondbus bar has a shape corresponding with a shape of the second cavity. 15.The apparatus according to claim 7, wherein the first cavity is coplanarwith the second cavity.
 16. A battery system comprising: a backbonecomprising: a first panel including a first upper surface and a firstlower surface; wherein the first upper surface includes a first cavityextending into the first upper surface towards the first lower surface;a first bus bar within the first cavity, the first bus bar including afirst coupling element and a second coupling element; a second panelhaving a second lower surface in direct contact with the first uppersurface; and wherein the second lower surface extends over a substantialportion of the first cavity; a first bay for a first battery module, thefirst bay comprising a first guide pin, wherein the first couplingelement extends into the first bay; and a second bay for a secondbattery module, the second bay comprising a second guide pin, whereinthe second coupling element extends into the second bay.
 17. The batterysystem according to claim 16, wherein the first battery module ispositioned within the first bay; wherein the first battery moduleincludes a first guide pin socket, a first terminal, and a secondterminal; wherein a mechanical coupling of the first guide pin and thefirst guide pin socket positions the first terminal within the firstbay; and wherein the first cavity positions the first coupling elementto align with the first terminal.
 18. The battery system according toclaim 17, wherein the second battery module is positioned within thesecond bay; wherein the second battery module includes a second guidepin socket, a third terminal, and a fourth terminal; wherein amechanical coupling of the second guide pin and the second guide pinsocket positions the third terminal within the second bay; and whereinthe first cavity positions the second coupling element to align with thethird terminal.
 19. The battery system according to claim 18, furthercomprising: wherein the first upper surface includes a second cavity;wherein the second cavity is spaced from the first cavity; a second busbar positioned within the second cavity, the second bus bar including athird coupling element and a fourth coupling element; wherein the secondlower surface extends over a substantial portion of the second cavity;and wherein the third coupling element extends into the first bay. 20.The battery system according to claim 19, further comprising: whereinthe mechanical coupling of the first guide pin and the first guide pinsocket positions the second terminal within the first bay; and whereinthe second cavity positions the third coupling element to align with thesecond terminal.